Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10S526/00—Synthetic resins or natural rubbers -- part of the class 520 series
  • Y10S526/906—Comminution of transition metal containing catalyst

Definitions

• organometallic compounds of aluminum used as one component in preparing the known catalysts have been, in practice and for the most part, the Al trialkyls and dialkyl Al halides, organometallic compounds of Al of the type R 2 AlOR' or RAL(OR') 2 have been mentioned generically.
• the catalysts obtained from such compounds as R 2 AlOR' as the organometallic component are either wholly inactive in the polymerization of olefins or exhibit low activity only at high temperatures above 100° C.
• Al compounds of that type R 2 AlOR'
• R' is an alkyl radical such as methyl, ethyl, propyl, etc., or an aryl radical such as phenyl.
• Organometallic compounds of Al of the formula RAl(OR') 2 yield catalysts which are quite inactive in the polymerization of olefins, even at high temperatures.
• An object of the present invention was to provide new catalyst-forming components having the formula R 2 AlOR" and/or RAl(OR") 2 which, with transition metal compounds, yield catalysts which are highly active in the polymerization and copolymerization of olefins.
• R 2 AlOR" and RAl(OR") 2 in which R" has structure (I) or (II) there are present, in positions 2 and 6 in structure (I) and in position 2, and optionally also in position 8, in structure (II), radicals at least one which is capable of providing a steric hindrance higher than that of the group --C 2 H 5 and, when the radicals in said two positions are different, the other radical being an alkyl radical such as methyl, ethyl, propyl and the like, or an aryl radical such as phenyl.
• the radicals which exhibit a steric hindrance higher than that of --C 2 H 5 present in either one or both of the two positions mentioned, are generally alkyl radicals and preferably branched alkyls containing 3 or more carbon atoms. Examples of such radicals are: --iC 3 H 7 ; --n.C 4 H 9 ; --t.C 4 H 9 , isoamyl, neopentyl, and the like.
• reaction can be carried out in a hydrocarbon solvent at room temperature or higher.
• the final catalysts of the invention are prepared from starting components which comprise (A) the new catalyst-forming components which are the compounds R 2 AlOR" or RAl(OR") 2 as defined herein and (B) compounds of transition metals.
• the organometallic Al compounds, R 2 Al(OR") and RAl(OR") 2 can be partially complexed with electron-donor compounds as described, for example, in the pending appl. Ser. No. 503,765 of Giannini, 6/9/74 now abandoned.
• Catalyst-forming components (B) comprise transition metal compounds such as halogenated Ti compounds, e.g., TiCl 4 , TiBr 4 , 3TiCl 3 .AlCl 3 , Ti halo-alcoholates, etc., Ti alcoholates; vanadium or zirconium halides such as VCl 4 , VOCl 3 , ZrCl 4 , etc., and similar transition metal compounds; or complexes of the formula
• M mg, Mn and/or Ca
• m a number from 0.5 to 2.0, inclusive;
• M' ti, V and/or Zr
• Y one or more atoms or groups, either the same or different, selected from halogen atoms, halogen atoms and, contemporaneously, oxygen atoms, --NR 2 , --OR, --Sr, ##STR5## groups, in which R is a hydrocarbon radical, in particular an alkyl, aryl, cycloalkyl or aralkyl radical; acetylacetonate anion; acetylacetonate anion and, contemporaneously, oxygen atoms; such atoms or groups being present in an amount sufficient to satisfy the valency of M';
• n is a number from 0.5m to 20m, inclusive.
• E an electron-donor compound selected from the following classes of compounds:
• a part of the Ti, V and/or Zr may be substituted by Al in such amount that the atomic ratio between Al and the other metals is from 0.1:1 to 2:1, inclusive.
• catalyst-forming components (B) comprising compounds of the transition metals
• solid products containing, besides the transition metal, also magnesium and a halogen, selected from chlorine and bromine and characterized at least either by a surface area larger than 3 m 2 /g or by an X-rays spectrum showing a halo, the intensity peak of which is at a lattic distance d comprised between 2.43 and 3.20 A, when chlorine is contained in the catalyst component in a Cl/Mg ratio ⁇ 1; conversely, when the catalyst component contains bromine in a Br/Mg ratio ⁇ 1, the halo is at a distance d comprised between 2.80 and 3.25 A.
• the catalyst components containing a transition metal, magnesium and a halogen can be prepared according to various methods.
• a preferred method consists in subjecting a mixture comprising a transition metal and anhydrous magnesium chloride or bromide to a grinding treatment, at least until the surface area becomes larger than 3 m 2 /g or until there appears, in the X-ray spectrum of the ground product, a halo, the intensity peak of which is in one of the ranges specified above.
• the catalyst components containing the transition metal, magnesium and the halogen may be prepared by reacting a liquid halogenated compound of the transition metal with a magnesium oxygenated compound such as, for instance, MgO, Mg(OH)Cl, magnesium carbonate, or MgX(OR), in which X is halogen and R is an alkyl or aryl radical containing from 1 to 15 carbon atoms, inclusive.
• a magnesium oxygenated compound such as, for instance, MgO, Mg(OH)Cl, magnesium carbonate, or MgX(OR), in which X is halogen and R is an alkyl or aryl radical containing from 1 to 15 carbon atoms, inclusive.
• the reaction may be conducted either in the presence or absence of an inert hydrocarbon diluent, at a temperature generally ranging from 20° to 150° C.
• halogenated compounds of titanium, vanadium or zirconium selected in particular from amongst TiCl 3 , TiCl 4 , VCl 4 , VOCl 3 , halo-alcoholates of titanium, ZrCl 4 and other similar compounds.
• the compounds according to this invention are less reactive than the aluminum trialkyls towards oxygen, and therefore they are less hazardous since, unlike the Al trialkyls, they are not flammable;
• compound R"OH preferably employed for preparing R 2 AlOR" or RAl(OR") 2
• the last-mentioned operation permits an intimate contact of the polymer with the additive so as to enable it to efficaciously exert its stabilizing action.
• the polymerization of olefins, and especially of ethylene and/or alpha-olefins, with the catalysts prepared, according to this invention, from compounds of the type R 2 AlOR" or RAl(OR") 2 is generally conducted according to known methods, by operating in a gas phase or in a liquid phase, either in the presence or absence of an inert hydrocarbon diluent.
• the polymerization temperature is generally comprised between 0° and 120° C, preferably between 50° and 90° C.
• the Al/transition metal ratio may vary over a wide range. In general it is preferable to operate with the ratio of from 5 to 100,000, inclusive.
• Hydrogen (7 atm.) and ethylene (6 atm.) were introduced into the autoclave until a total pressure of 13 atm. was reached and which was kept constant during the polymerization by feeding ethylene continuously.
• Example 1 was repeated using, as catalyst-forming, component (B), 24 mg of the product prepared by dry cogrinding, in a steel ball mill, TiCl 4 and anhydrous MgCl 2 in such a ratio as to have a titanium content of 3.9% by weight. In this way, 390 g of polyethylene (420,000 g of polymer/g of titanium), having an inherent viscosity of 1.55 dl/g, were obtained.
• Example 2 was repeated, using 9.4 mg of the catalyst-forming component (B) and starting from a gaseous mixture consisting of 9 atm. of ethylene and 4 atm. of hydrogen. 280 g of polyethylene (760,000 g of polymer/g of titanium), having an inherent viscosity of 2.55 dl/g, were obtained.
• Example 3 was repeated using 20 mg of the catalytic component containing titanium and magnesium, and the solution of compound R 2 ALOR" in which R" is 2,6-dimethylphenyl prepared as above. In this run however, only 2 g of polyetylene were obtained.
• TiCl 4 -ethylbenzoate and anhydrous MgCl 2 were dry coground in such a ratio as to have a titanium content of 5% by weight. On X-rays examination, the coground product had a spectrum similar to that of the catalytic component of Example 1.
• the polypropylene thus obtained was isolated by treatment of the polymerization reaction mass with methanol and acetone. It amounted to 435 g (88,000 g of polymer/g of titanium). The polymer exhibited an inherent viscosity of 1.67 dl/g and, on extraction with boiling heptane, (36 hours in a Kumagawa apparatus) left a heptane insoluble (isotactic) residue of 54.5%.
• Example 4 Using 97 mg of a catalyst forming component containing titanium and magnesium as in Example 4, and the solution of (C 2 H 5 ) 2 Al-(2,6-di-ter.butyl-paracresoxy) as co-catalyst, after a 5-hour polymerization under the conditions of Example 4, 105 g of polypropylene (22,000 g of polymer/g of titanium), having an inherent viscosity of 2.13 dl/g and a residue, on extraction with heptane, of 89.6%, were obtained.
• Example 4 was repeated, employing 47.4 mg of the catalyst-forming component containing titanium and magnesium, and 7 ml of the solution of compound (iso-C 4 H 9 ) 2 Al-(2,6-di-ter.butyl-paracresoxy) as co-catalyst. After a 5-hour polymerization at 80° C, 61 g of polypropylene (26,000 g of polymer/g of titanium), having an inherent viscosity of 1.11 dl/g and a residue, on extraction with heptane, of 70.5% were obtained.
• Example 3 was repeated, using 20 mg of the catalyst-forming component (B) and, as component (A) or co-catalyst, the foregoing solution. 98 g of polyethylene (125,000 g of polymer/g of titanium) were thus obtained.
• Example 3 was repeated, employing 21 mg of the catalyst-forming component (B) and the solution described hereinbefore as co-catalyst. 240 g of polyethylene (288,000 g of polymer/g of titanium) were obtained.
• Example 3 was repeated, employing 19 mg of catalyst-forming component (B) and 80 ml of the foregoing solution as cocatalyst. In this way, 60 g of polyethylene (81,000 g of polymer/g of titanium) were obtained.

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• Chemical & Material Sciences (AREA)
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• Transition And Organic Metals Composition Catalysts For Addition Polymerization (AREA)

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• 1975
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